Roof flashing strip and method of production

ABSTRACT

A flashing strip is defined by at least a pair of interlocking flashing segments. Each of the segments has first and second intersecting legs, the first legs of each of the segments are brought into abutment and interlocked either by folding over into inter-engagement or by providing an embossment in each of the upper legs which are then, upon deforming of one of the first legs, and folding it over the upper edge of the second leg and mating the embossments together. Preferably, a gap is provided between the second legs of the first and second segments to define a gap for inserting a shingle therewithin.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a completion application of co-pending U.S. provisional patent application Ser. No. 60/675,421, filed Apr. 27, 2005, the entire disclosure of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to flashing strips such as for waterproofing roofs, sealing around windows, or configurable to other such waterproofing and sealing uses. More particularly, the present invention pertains to prefabricated flashing strips used to form a weather tight barrier, the strips being either preassembled into a one-piece sealing strip that is then put in place or in situ positioned, interconnected and formed into an elongated sealing strip. The invention also pertains to a method of manufacture of a roof flashing strip.

2. Description of the Prior Art

U.S. Pat. No. 5,946,862, incorporated herein by reference, discloses a chimney flashing system and a method of production. According to U.S. Pat. No. 5,946,862, a plurality of individual metal L-shaped “flashing cards” are assembled into a linear array to facilitate the installation of roof shingles or the like. The flashing cards are assembled together wherein partially overlapping cards are adhered or affixed to one another. An adhesive is used to bond one card to another or they are otherwise secured together with stables, tape or the like.

It is to be appreciated that adhering a plurality of individual flashing cards together is time consuming as regards the steps of positioning the flashing cards and depositing an appropriate amount of bonding material in serial fashion. A disadvantage of such installation is that adhesives are typically temperature dependent. As such, the use of adhesive may place a limit on the season when the flashing cards are installed. That is, if the day is too hot or too cold, the adhesive may not completely cure. Further, even under ideal conditions, adhesives require time to cure or become set.

Desirably, a flashing card that overcomes temperature dependence would be desirable. Further, the flashing card would enable in situ or preassembled installations.

SUMMARY OF THE INVENTION

According to this invention, there is provided a segmented flashing strip and a method of making the flashing strip. The flashing strip comprises at least a pair of generally L-shaped flashing segments, each of said flashing segments having a pair of intersecting planar first and second legs and laterally spaced first and second end portions, the first end portion of one of said flashing segments partially overlapping the second end portion of the other of said flashing segments, each of the first legs in the overlapping end portion are abutted with one another and have a deformable leg portion, and the deformable leg portions of said flashing segments are deformed into interengagement with one another and the first legs interlocked with one another.

According to one preferred embodiment, the first legs are each substantially rectangular, the first end portion of one of said first legs includes an uppermost end portion that defines a deformable and foldable flap that is folded onto, about, and into engagement with the corresponding uppermost end portion of the other first leg.

According to another preferred embodiment, the first legs are each substantially rectangular, the first legs are substantially alike and abutted with one another, and at least one embossment is provided in the overlapped end portions whereby to interlock the pair of flashing segments together. Preferably, more than one embossment is provided in the abutted overlapped end portions.

The flashing segments are preferably formed of a metal selected from the group consisting of aluminum, brass, tin, galvanized steel, and copper.

Further and according to this invention, there is provided a method of making a flashing strip, comprising the steps of providing a pair of generally L-shaped flashing segments, each said flashing segment having a pair of intersecting planar first and second legs and laterally spaced first and second end portions, partially overlapping the first end portion of one of said flashing segments with the second end portion of the other of said flashing segments, abutting the overlapping end portions of the first legs, each said first leg having a deformable end portion, and deforming the deformable leg portions of said first legs in a manner that the deformable leg portions are deformed into interengagement with one another and the first legs interlocked with one another.

In a preferred method according to this embodiment of the invention, an upper end portion of one first leg defines a flap portion that is disposed higher than the upper end portion of the other first leg, and the steps of the method include folding the flap portion over and about, downwardly, and into engagement against the backside of the other first leg, and folding the interengaged upper end portions downwardly and into engagement against the backside of the other first leg.

In an alternate preferred method, the steps include deforming the overlapped end portions in a manner to form an interlocking bead or embossment.

Typically, when used for roofing installations, the upper first legs are interlocked with one another in a manner that the lower second legs are separated by a predetermine amount suitable for receiving a roofing shingle therebetween, whereby to seal about the sides of a chimney.

The present invention will be more clearly understood with reference to the accompanying drawings and to the following Detailed Description, in which like reference numerals refer to like parts and where:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a chimney structure incorporating a flashing strip in accordance with the present invention.

FIGS. 2A and 2B are perspective views illustrating two flashing cards being assembled into a flashing strip.

FIGS. 3A, 3B and 3C are side views, in cross-section, illustrating the interconnecting of two flashing cards to one another.

FIGS. 4A and 4B are sides views, in cross-section, illustrating an alternate method of interconnecting of two flashing cards to one another.

DETAILED DESCRIPTION OF THE PREFERED EMBODIMENT

Turning now to the drawings, FIG. 1 illustrates a preferred embodiment of a chimney flashing system 10 including a flashing strip 12 for sealing a chimney 14 on a roof 16 against water leakage. The chimney 12 projects upwardly from the roof 16 and has a vertical side 18. The roof 16 is comprised of a plurality of separate tiles or shingles 20

The flashing strip 12 is shown in connection with sealing the junction between the base of the chimney 14 and the shingles 20. It is to be understood that the flashing strip may also be used to advantage in sealing the periphery about a skylight, a window, and like openings exposed to water and air penetration.

The flashing strip 12 comprises a succession of separate L-shaped flashing cards or segments 22 which are interconnected to form an elongated member of any desired length. In use, preferably, the flashing strip 12 has a length ranging from about 6 feet to about 10 feet. As currently produced, the legs of a flashing card typically measures between 8 inches to 10 inches on a side, although other sizes and configurations may be used in the preferred embodiment of this invention.

To ensure conforming fitment of the L-shaped form onto the sloping surfaces of a roof circumjacent to the upwardly extending chimney, the material is thin to enhance formability. In this regard, the flashing card material can range from about 2 mils to about 400 mils, and preferably about 30 mils to about 200 mils.

The flashing cards are generally formed from a durable, pliable, and corrosive resistant material. Suitable materials include, but are not limited to, aluminum, tin, brass, copper, lead, and galvanized steel.

Each L-shaped flashing card or segment 22 has a pair of intersecting planar, preferably rectangular shaped, legs 24 and 26. When supplied, the legs are generally disposed at 90° to one another. However, because of the pliability of the material, the legs may be bent relative to one another so that the flashing strip will conform to the angle of the roof circumjacent to the sides of the chimney.

What is critical hereto is that the material selected for use herein has sufficient durability to withstand weathering for an extended period of time and at the same time have a sufficient degree of pliability, if necessary, to enable a tile or shingle 20 to be inserted in the gap 28.

A method of assembly is shown and described in FIGS. 2A-2B and FIGS. 3A-3C. As discussed herein, the legs 24 are secured to the roof and the legs 26 extend upwardly and juxtaposed in parallel relation against a side 18 of the chimney.

Turning first to FIGS. 2A and 2B, consecutive like shaped flashing cards or segments 22 and 22′ are positioned adjacent to one another in spaced, partially overlapping relationship with one another. That is, the L-shaped end portion 22 a of the flashing card 22 overlaps an L-shaped end portion 22 b of the flashing card 22′. It is contemplated that the extent of L-shaped overlap 22 a and 22 b between the respective L-shaped end portions of the legs 24 and 26 of consecutive flashing cards 22 and 22′ will vary between 2 inches and 20 inches, depending on the application and the respective lengths of the legs.

Preferably and according to this invention, the overlapped end portions of the upstanding legs 26 of the flashing cards 22 and 22′ are fixedly secured to one another, in a manner to be described herein below.

Preferably and according to this invention, the legs 24 of the flashing strip 12 are spaced from one another by a small amount or gap, indicated by the number 28. The gap 28 is to provide a cavity 30 for receiving a roof shingle 20 inserted therewithin. In this regard, during attachment of adjoining flash cards, a spacer (not shown) may be placed between the legs 24 to ensure that the gap and associated cavity is uniform and suitable for fitment about the roofing shingle.

It is to be understood that consecutive flashing cards, when used for weather sealing about a window or like closure, the legs 24 and 26 of the flashing cards 22 and 22′ may both be in contacting relation. That is, the gap or vertical separation between the legs 24 is not needed.

Preferably and according to this invention, FIGS. 3A, 3B, and 3C illustrate an interconnection between the consecutive flashing strips 22 and 22′ whereby to form the elongated flashing strip 12. As shown best in FIG. 3A, the upper leg 26 of the flashing card 22 is elevated to be somewhat higher than the upper leg 26 of the flashing card 22′. That is, the flashing card 22 has an elongated, generally rectangular, upper end portion or flap or flap portion 32 that extends above the upper edge 34 of the flashing card 22′.

The flap 32 is bent over the edge 34, in the direction of the arrow “A”, downwardly, and against the back surface 36 of the leg 26 of the flashing card 22′. Due to the pliability of the flashing card material, a tool such as a conventional pair of pliers may be used to bend the flap.

The result of bending the flap is shown in FIG. 3B. So bent, the flap 32 and an upper end portion of the flashing strip 22′ are interlocked by an elongated bead or seam 38. The portion shown in phantom represents the initial position of the flap 32. The flap 32 and leg portion 26 of the flashing card 22 form a strong elongated frictional gripping hold about the upper end portion of the leg portion 26 of the flashing card 22′.

The seam 38 is then folded, in the direction of the arrow “B”, rearwardly, downwardly, and against the back surface 36 of the leg 26 of the flashing card 22′. The upper end portions of the legs 26 of the two flashing cards 22 and 22′ cooperate to form an enhanced locking bead or seam 40. The portions shown in phantom represent the initial positions of the flap and leg 26 of the flashing card 22′.

As shown in FIG. 3C, and in use, a shingle 20 is seated in the gap 28. The shingle has a bottom surface 42 seated atop the upper surface of the lower leg 24 of the flashing card 22′ and an inward edge 44 proximal, and possibly abutted against, the upper leg 26 of the flashing card 22′.

Although the seam or bead is shown folded backwardly and downwardly, whereby the bead or seam is juxtaposed against the side 18 of the chimney, the procedure could be reversed. That is, the foldable flap would be defined by the leg portion 26 of the flashing card 22′ that extends upwardly from the top edge of the leg 26 of the flashing card 22. As before, the flap would be folded downwardly and onto the front surface of the leg 26 of the flashing card 22, whereby to form a bead, and the bead further folded.

In use, the flashing strip 12 may be assembled and formed in place (i.e., in situ), against the base of the chimney. That is, as described above, a first then a second flashing card 22 and 22′ are positioned together, in overlapped relation and provided with a roofing shingle 20 in the gap 28 between the legs 24. The legs 24 are secured to the roof by nails so that the other legs 26 extend upwardly from the roof along the bottom of the chimney. The upstanding end portions of the legs 26 are interlocked by the seam 38 or 40.

Alternatively, the flashing cards 22 and 22′ may be assembled, away from the chimney, interlocked and formed into an assembly, and the assembly taken to the roof, positioned against the base of the chimney, secured thereto, and operatively associated with the roofing tiles.

It is also to be appreciated that by forming an elongated flashing strip 12 from individual segments of flashing, it is possible to assemble and cut the assembled flashing strip to any desired length, and the strip then carried to the desired installation.

The flashing strip 12 may be secured or bonded to the roof and chimney surfaces via suitable bonding material such as tar, adhesive or the like to prevent any moisture from seeping in between the surfaces to which the strip is secured. Because the flashing strip is essentially a continuous strip, there is no need to provide a seal between adjacent flashing cards, thus reducing the labor necessary to manufacture the flashing strip or complete a sealed installation.

In manufacturing the flashing strip, the degree of overlap 22 a and 22 b may vary depending on the need to accommodate various sizes of shingles. If, for example, a roof is to be manufactured from small shingles, the legs would overlap from about 5 to about 7 inches. In this way, more shingles may be placed upon the roof, which would be necessary due to the small size of the shingles. On the other hand, if the shingles were exceptionally large on the magnitude of about 18 inches, then the flashing strip would have the individual legs overlapping between 1 and 4 inches. Clearly, intermediate size shingles may also be used with the flashing strip hereof

Another preferred embodiment according to this invention is illustrated in FIGS. 4A and 4B. As described herein above, the flashing strip 12 is formed by overlapping the end portions of consecutive flashing cards 22 and 22′ and forming a gap 28 between the superposed legs 24 for receiving a shingle or tile inserted into the gap.

In this embodiment, the L-shaped flashing cards 22 and 22′ are substantially identical. That is, the lower legs 24 have like extensions and the upper legs 26 have like extensions. Preferably and according to this embodiment of the invention, the upper legs 26 are interlocked by an indentation or embossment 46.

The embossment or indentation 46 may be provided by many conventional tools and indentor configurations. As illustrated in FIG. 4A, a tool 48 has a pair of closable jaws 50 and 52, which jaws are brought into closed relation when moved in the direction of the arrow “C”. The jaws 50 and 52 are provided, respectively, with a raised indentor head or protuberance 50 a and recess 52 a with the recess 52 a being positioned to receive the indenter head 50 a.

As illustrated, the indentor head and matching recess are generally hemispherically shaped. It is to be appreciated that the head and recess may be shaped in the form of a cone, star, square, rectangle, or wedge, and if elongated, extending in a preferred direction—such as horizontally or vertically. A suitable geometry could desirably inhibit flexure between consecutively interlocked flashing cards.

In operation, the jaws 50 and 52 are driven towards and against the legs 26 of the flashing cards 22 and 22′. The force of the jaws is of such amount that the indenter head 50 a will force the material of the two legs 26 into the recess 52 a, inelastically deform the legs, and form the embossment 46 in each leg.

As shown in FIG. 4B, the embossment 46 interlocks the flashing cards 22 and 22′. While a single embossment 44 is formed, more can be provided, as desired.

It is apparent that the flashing strip of the present invention provides several advantages over currently available flashing cards and flashing strips in that a series of two or more individual cards form a continuous one-piece product, which may be made to any desired size; and prevents water damage.

It is apparent from the preceding that there has been described herein a flashing strip and a method of manufacture, therefor, that is easy to use and reduces the time necessary to manufacture same over prior systems. 

1. A flashing strip comprising: at least a pair of generally L-shaped flashing segments, each of said flashing segments having a pair of intersecting planar first and second legs and laterally spaced first and second end portions, the first end portion of one of said flashing segments partially overlapping the second end portion of the other of said flashing segments, each of the first legs in the overlapping end portions are abutted with another and have a deformable leg portion, the deformable leg portions of said flashing segments being deformed into inter-engagement with one another and the first legs being interlocked with one another.
 2. The flashing strip of claim 1 wherein: the first legs are each substantially rectangular, the first end portion of one of said first legs includes an uppermost end portion that defines a deformable and foldable flap that is foldable onto, about and into engagement with the corresponding uppermost end portion of the other first leg.
 3. The flashing strip of claim 1 wherein the first legs of each of the at least a pair of segments are substantially alike and abutted with one another, at least one embossment being provided in the overlapped end portions of each the first legs to interlock the pair of flashing segments together.
 4. The flashing strip of claim 1 wherein the flashing strip has a length ranging from about six feet to about ten feet.
 5. The flashing strip of claim 1 wherein the second legs of each of the segments are spaced from one another to define a gap therebetween, the gap accommodating a roof shingle therewithin.
 6. The flashing strip of claim 1 wherein the flashing strips are interlocked by an elongated bead extending along the length thereof.
 7. A method of making a flashing strip, comprising: At least a pair of generally L-shaped flashing segments, each of said flashing segments having a pair of intersecting planar first and second legs and laterally spaced first and second end portions, partially overlapping the first end portion of one of said flashing segments with the second end portion of the other of said flashing segments, abutting the overlapping ends portions of the first legs, each of said first legs having a deformable end portion, and deforming the deformable leg portions of said first legs in a manner such that the deformable leg portions are deformed into inter-engagement with one another thereby interlocking the first legs with one another.
 8. The method of claim 7, wherein: an upper end portion of one of the first legs defines a flap portion that is disposed higher than the upper end portion of the other first leg the method further comprising folding the flap portion over, about and into inter-engagement against the backside of the other first leg, and, thereafter folding the inter-engaged upper end portions downwardly and into engagement against the backside of the other first leg.
 9. The method of claim 7 which further comprises: disposing the upper first leg and the second lower second leg in space relationship to define a gap therebetween for receiving a roof shingle therebetween.
 10. The method of claim 7 which further comprises: providing at least one embossment in each of the first legs, one embossment projecting into the embossment of the other segment upon folding of the deformable flap over the first leg to interlock the first legs by the indentations. 